System For Producing Sterile Beverages And Containers Using Electrolyzed Water

ABSTRACT

A system and method of producing sterile beverages and containers, e.g., cleaning, sterilizing, and pre-sterilizing the bottles, the caps, and the critical surfaces using electrolyzed water. The sterilization system may include a mechanical sprayer that sprays electrolyzed water on the bottles, the caps, and the critical surfaces. In another embodiment, the sterilization system may include a fog generator connected to an electrolyzed water generator that produces a fog within a closed sterilization enclosure to sterilize the bottles, the caps, and the critical surfaces. Additionally, further, in yet another embodiment, the sterilization system may include an electrostatic fog generator connected to an electrolyzed water generator that produces an electrostatic, positively-charged fog within a closed sterilization enclosure. The electrostatic, positively-charged fog is attracted to the negatively charged or grounded bottles, caps, and critical surfaces to sterilize the bottles, the caps, and the critical surfaces.

FIELD OF THE INVENTION

This invention relates generally to a method and a system for producingsterile beverages and containers, e.g., cleaning, sterilizing, andpre-sterilizing the containers, caps, and critical surfaces, and morespecifically to the sterilizing of the containers, caps, and criticalsurfaces using electrolyzed water.

BACKGROUND OF THE INVENTION

The two most common processes to produce sterile acid non-carbonatedbeverages without preservatives are hot fill and aseptic. Both of theseprocesses have inherent cost disadvantages and are not very sustainable.The hot fill process requires heavy weight bottles and excessive use ofwater resources. Additionally, the hot fill process is not economicaldue to the cost of petroleum based resins used to make the bottles. Theaseptic processes are inherently capital intensive and inefficient asthey require a high level of sophistication and built-in cycles that areassociated with increased line down time as compared to hot fill.

Additionally, one of the major disadvantages of current asepticprocesses is the need to sterilize all components of the package (caps,bottles) and assemble them in a controlled environment during bottlefilling to avoid secondary contamination. The critical surfaces that areexposed to product are also sterilized before the initiation of theproduction cycle. In the event of loss of sterility due to violation ofcritical control points, these surfaces need to be re-sterilized beforeinitiation of production. The current state of technology uses chemicalsto sterilize caps, bottles & critical surfaces. Chemicals used currentlyrequire a water rinse to remove the residual chemical to prevent anadulteration issue. Recently, there have been developments to allowElectron Beam (E-Beam) based systems to accomplish the sterilization ofthe caps and the bottles. However, these systems are expensive andrequire more extensive health and safety requirements.

Thus, while various methods and systems for producing sterile beveragesand containers according to the prior art provide a number ofadvantageous features, they nevertheless have certain limitations. Thepresent invention seeks to overcome certain of these limitations andother drawbacks of the prior art, and to provide new features notheretofore available.

SUMMARY OF THE INVENTION

Accordingly, there is provided a sterilization system used to achievesterile beverages and sterilize bottles and caps, wherein the bottlescontain the sterile beverage and the caps cover the bottles, thesterilization system comprises: a bottle sterilizer for sterilizing thebottles, wherein the bottle sterilizer discharges electrolyzed wateronto the bottles; a cap sterilizer for sterilizing the caps, wherein thecap sterilizer discharges electrolyzed water onto the caps; and a fillerstation that includes a filler sterilizer and a filler that fills thebottles with the beverage and caps the bottles, wherein the fillersterilizer sterilizes the filler station before the initiation ofproduction by discharging electrolyzed water on the product-contactsurfaces. Additionally, the bottle sterilizer, the cap sterilizer, andthe filler sterilizer may include a mechanical sprayer that includesnozzles that discharge a spray of electrolyzed water onto the bottles,the caps, and the product-contact surfaces respectively. Also, thebottle sterilizer, the cap sterilizer, and the filler sterilizer mayinclude a mechanical fog generator that discharges a fog of electrolyzedwater onto the bottles, the caps, and the product-contact surfacesrespectively. Further, the bottle sterilizer, the cap sterilizer, andthe filler sterilizer may include an electrostatic fog generator thatdischarges an electrostatically charged fog of electrolyzed water ontothe bottles, the caps, and the product-contact surfaces respectively.

In another embodiment according to this invention, a sterilizationsystem used to achieve sterile beverages and sterilize bottles and caps,wherein the bottles contain the sterile beverage and the caps cover thebottles, the sterilization system comprises: an electrolyzed watergenerator that produces electrolyzed water; a bottle station forsterilizing the bottles, the bottle station includes a bottle loader forloading the bottles, a bottle conveyor for transporting the bottles, anda bottle rinser connected to the electrolyzed water generator thatsprays the electrolyzed water onto the bottles; a cap station forsterilizing the caps, the cap station includes: a cap loader for loadingthe caps, a cap conveyor for transporting the caps, and a cap rinserconnected to the electrolyzed water generator that sprays theelectrolyzed water on the caps; a filler station connected to the bottlestation and the cap station, wherein the filler station includes afiller with critical surfaces that are potential product-contactsurfaces during the filling operation, and wherein the filler fills thebottles with the beverage and caps the bottles after the bottles arefilled with the beverage, and wherein the filler station furtherincludes a spray device connected to the electrolyzed water generatorthat sprays the electrolyzed water onto the critical surfaces of thefiller. The sterilization system may further include a sterilizationenclosure that fully encloses the filler that maintains asepticconditions for the bottles, the caps, and the critical surfaces, whereinthe sterilization enclosure may include a HEPA air filter to providepositive air pressure and proper air flow regimes throughout thesterilization enclosure.

In another embodiment according to this invention, a sterilizationsystem used to achieve sterile beverages and sterilize bottles and caps,wherein the bottles contain the sterile beverage and the caps cover thebottles, the sterilization system comprises: a bottle station thatincludes a bottle loader for loading the bottles and a bottle conveyorfor transporting the bottles; a cap station that includes a cap loaderfor loading the caps and a cap conveyor for transporting the caps; afiller station connected to the bottle station and the cap station,wherein the filler station includes a filler with critical surfaces thatare potential product-contact surfaces during the filling operation, andwherein the filler fills the bottles with the beverage and caps thebottles after the bottles are filled with the beverage; a sterilizationenclosure that fully encloses the filler, wherein the sterilizationenclosure maintains aseptic conditions for the bottles, the caps, andthe critical surfaces; an electrolyzed water generator that produceselectrolyzed water; a fog generator connected to the electrolyzed watergenerator, wherein the fog generator produces a fog of electrolyzedwater that is dispersed within the sterilization enclosure, wherein thefog of electrolyzed water sterilizes the bottles, caps, and criticalsurfaces. Additionally, the fog generator may produce an electrostatic,positively-charged fog of electrolyzed water, wherein the bottles, thecaps, and the critical surfaces are negatively charged or grounded,thereby the bottles, the caps, and the critical surfaces attract theelectrostatic, positively-charged fog of electrolyzed water.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic view of a sterilization system according to thepresent invention;

FIG. 1B is an exploded schematic view of a bottle station of thesterilization system depicted in FIG. 1A according to the presentinvention;

FIG. 1C is an exploded schematic view of a cap station of thesterilization system depicted in FIG. 1A according to the presentinvention;

FIG. 1D is an exploded schematic view of a filler station of thesterilization system depicted in FIG. 1A according to the presentinvention;

FIG. 2 is a side-view of the bottle station of the sterilization systemdepicted in FIGS. 1A and 1B according to the present invention;

FIG. 3 is a side-view of the cap station of the sterilization systemdepicted in FIGS. 1A and 1C according to the present invention;

FIG. 4A is a schematic view of an alternative embodiment of a capstation of the sterilization system depicted in FIG. 1A;

FIG. 4B is a side-view of the cap station depicted in FIG. 4A;

FIG. 5 illustrates an alternative embodiment of a sterilization systemaccording to the present invention;

FIG. 6 illustrates an alternative embodiment of a sterilization systemaccording to the present invention;

FIG. 7 illustrates an alternative embodiment of a sterilization systemaccording to the present invention; and

FIG. 8 illustrates an alternative embodiment of a sterilization systemaccording to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1A illustrates a first embodiment of the invention, a sterilizationsystem 100 used to achieve sterile beverages and to sterilize containersor bottles 102, caps 104, and critical surfaces. The bottles 102 maycontain the sterile beverage and the caps 104 may cover the bottles 102.The critical surfaces generally include those surfaces on the equipmentthat come in contact with the product or product-contact surfaces andthereby must be sterile to maintain and produce sterile beverages. Inone exemplary embodiment, the sterilization system 100 generallyincludes a bottle station 120, a cap station 140, and a filler station160. The sterilization system 100 may utilize electrolyzed water tosterilize the bottles 102, the caps 104, and critical surfaces.

Electrolyzed water may be produced by an electrolyzed water system or anelectrolyzed water generator 110 known and used in the art, such asthose provided by various suppliers and/or manufacturers. For example,the electrolyzed water generator 110 may be an Ecaflo™ model (such asAQ50) manufactured and/or sold by Trustwater™ to produce theelectrolyzed water. Generally, one exemplary process that produceselectrolyzed water consists of passing water of varying mineralizationthrough an electrochemical cell which results in two distinctelectrically opposite streams, a negatively charged solution and apositively charged solution. The negatively charged solution and thepositively charged solution may be mixed to modulate the pH and affectthe sanitizing functionality of the electrolyzed water forsterilization. Additionally, there are other methods, processes, and/orsystem that may produce electrolyzed water for the sterilization system100 without departing from this invention. The electrolyzed watergenerator 110 should be capable of producing electrolyzed water at aconcentration range of approximately 50-1000 parts-per-million (PPM) asmeasured as free chlorine and a temperature range of approximately 10-65degrees Celsius. The electrolyzed water generator 110 may deliver ahigher conversion of the sodium chloride in the electrolysis process andproduce electrolyzed water with reduced chloride content. Lower chloridecontent is required to minimize any corrosion issues in the beveragefilling system.

As illustrated in FIGS. 1A and 1B, the sterilization system 100 mayinclude the bottle station 120. The bottle station 120 may include abottle loader 122, a bottle conveyor(s) 124, and a bottle rinser 126.The bottle loader 122 may consist of a container that holds fully formedunsterilized or unsanitized empty bottles 102. Additionally, the bottleloader 122 may include a device (not shown) within the container toautomatically load the bottles 102 on to the bottle conveyor 124. Anexemplary configuration of the bottle station 120 will be describedbelow. The bottle station 120 may be other types and/or configurationsof bottle stations without departing from this invention.

The bottler rinser 126 may include a bottle spray device 128 and abottle rinser conveyor 130. A side view of the bottle rinser 126 isillustrated in FIG. 2. Generally, the bottle rinser 126 may spray ordispense a liquid on the bottles 102 as the bottles 102 pass through agiven location. Specifically, the bottle rinser 126 may sprayelectrolyzed water on the bottles 102 as the bottles 102 pass through abottle enclosure 134. The bottle spray device 128 may include one ormore nozzles 132 to spray electrolyzed water onto the bottles 102 bothinternally and externally.

The bottle rinser 126 may spray electrolyzed water on the bottles 102 tosterilize or sanitize the bottles 102 internally and externally prior tofilling the bottles 102. Specifically, the nozzles 132 spray a pre-setamount of electrolyzed water on the bottles 102. The bottle spray device128 of the bottle rinser 126 may be connected or associated with anelectrolyzed water generator 110. In one embodiment of the invention,the nozzles 132 may spray electrolyzed water at a low concentration, lowtemperature, and a high dwell time. For example, the nozzles 132 mayspray electrolyzed water at a concentration range of approximately 50 to100 PPM as measured as free chlorine, a temperature range ofapproximately 10 to 30 degrees Celsius, and a time range ofapproximately 5-30 minutes dwell time. In another embodiment of thisinvention, the nozzles 132 may spray electrolyzed water a highconcentration, high temperature, and a low dwell time. For example, thenozzles 132 may spray electrolyzed water at a concentration range ofapproximately 100 to 1000 PPM as measured as free chlorine, atemperature range of approximately 25 to 65 degrees Celsius, and a timerange of approximately 5 to 30 seconds dwell time.

The bottle rinser conveyor 130, as illustrated in FIGS. 1A and 1B, maybe a linear conveyor. The linear bottle rinser conveyor 130 is inlinewith the other conveyors leading to the filler station 160.Additionally, the bottle rinser conveyor 130 may be configured to invertthe position of the bottles 102, so that the opening of the bottles 102are downwardly or side facing when the bottles 102 pass by the nozzles132. At this point, the bottles 102 may then be sprayed by the nozzles132. Once the bottles 102 are sprayed with electrolyzed water, thebottle rinser conveyor 130 may then again invert the position of thebottles 102 to an upright position with the opening facing upwardly.

Additionally, without departing from this invention, the bottle rinser126 may include a bottle enclosure 134. The bottle enclosure 134 may beused to contain the electrolyzed water spray. The bottle enclosure 134may include panels that surround an area around or associated with thearea around the bottle spray device 128 and the bottle rinser conveyor130. The bottle enclosure 134 may also be a cabinet surrounding thespraying area on the bottles 102.

During the spraying of the bottles 102 with electrolyzed water, thebottles 102 may contain a small residue of the electrolyzed water thatmay remain after the sterilization of the bottles 102. The electrolyzedwater inside the bottles 102 is not an adulteration issue or productsafety issue. In many cases, there is no significant sensory impact.However, to help remove this residue of electrolyzed water, a sterileair blower 136 may be included with the bottle rinser 126 withoutdeparting from the invention. The sterile air blower 136 may provide apressurized blow of sterile air inside the bottles 102. The sterile airblower 136 may provide the blow of sterile air when the bottle 102 isinverted with the opening facing downward or with the bottle uprightwith the opening facing upward. This blow of sterile air may besufficient to remove the majority of residual electrolyzed water.

Additionally, as illustrated in FIGS. 1A and 1C, the sterilizationsystem 100 may include a cap station 140. The cap station 140 mayinclude a cap loader 142, a cap conveyor(s) 144, and a cap rinser 146.The cap loader 142 may include a container that holds unsterilized orunsanitized caps 104. Additionally, the cap loader 142 may include adevice (not shown) within the container to automatically load the caps104 on to the cap conveyor 144. An exemplary configuration of the capstation 140 will be described below. The cap station 140 may be othertypes and/or configurations of cap stations without departing from thisinvention.

As further shown in FIG. 1C, the cap rinser 146 may include a cap spraydevice 148 and a cap rinser conveyor 150. A side view of the cap rinser146 is illustrated in FIG. 3. Generally, the cap rinser 146 may spray ordispense a liquid on the caps 104 as the caps 104 pass through a givenlocation. Specifically, the cap rinser 146 may spray electrolyzed wateron the caps 104 as the caps 104 pass through a cap enclosure 154. Thecap spray device 148 may include one or more nozzles 152 to sprayelectrolyzed water onto the caps 104.

The cap rinser 146 may spray electrolyzed water on the caps 104 tosterilize or sanitize the caps 104. Specifically, the nozzles 152 spraya pre-set amount of electrolyzed water on the caps 104. The cap spraydevice 148 may be connected or associated with an electrolyzed watergenerator 110. In one embodiment of the invention, the nozzles 152 mayspray electrolyzed water at a low concentration, low temperature, and ahigh dwell time. For example, the nozzles 152 may spray electrolyzedwater at a concentration range of approximately 50 to 100 PPM asmeasured as free chlorine, a temperature range of approximately 10 to 30degrees Celsius, and a time range of approximately 5 to 30 minutes dwelltime. In another embodiment of this invention, the nozzles 152 may sprayelectrolyzed water a high concentration, high temperature, and a lowdwell time. For example, the nozzles 152 may spray electrolyzed water ata concentration range of approximately 100 to 1000 PPM as measured asfree chlorine, a temperature range of approximately 25 to 65 degreesCelsius, and a time range of approximately 5 to 30 seconds dwell time.

The cap rinser conveyor 150, as illustrated in FIG. 1C, may be a linearconveyor. The linear cap rinser conveyor 150 is inline with the otherconveyors leading to the filler station 160. Additionally, the caprinser conveyor 150 may be configured to invert the position of the caps104, so that the caps 104 are downwardly or sideways facing when thecaps 104 pass by the cap spray device 148. At this point, the caps 104may then be sprayed by the nozzles 152. Once the caps 104 are sprayedwith electrolyzed water, the cap rinser conveyor 150 may then againinvert the position of the caps 104 to an upright position with the capfacing upwardly.

Additionally, without departing from this invention, the cap rinser 146may include a cap enclosure 154. The cap enclosure 154 may be used tocontain the electrolyzed water spray. The cap enclosure 154 may includepanels that surround an area around or associated with the area aroundthe cap spray device 148 and the cap rinser conveyor 150. The capenclosure 154 may also be a cabinet surrounding the spraying area on thecaps 104.

During the spraying of the caps 104 with electrolyzed water, the caps104 may contain a small residue of the electrolyzed water that mayremain after the sterilization of the caps 104. The electrolyzed waterinside the caps 104 is not an adulteration issue or product safetyissue. In many cases, there is no significant sensory impact. However,to help remove this residue of electrolyzed water, a sterile air blower156 may be included with the cap rinser without departing from theinvention. The sterile air blower 156 may provide a pressurized blow ofsterile air on or inside the caps 104. The sterile air blower 156 mayprovide the blow of sterile air when the cap 104 is inverted with theopening facing downward or with the cap upright with the opening facingupward. This blow of sterile air may be sufficient to remove themajority of residual electrolyzed water.

In another embodiment of the sterilization system, the cap station 140may include multiple cap loaders 142. Additionally, the cap rinser 146may be supplemented or replaced by submersing the caps 104 inelectrolyzed water while in the cap loader 142. The cap loader(s) 142may be filled with electrolyzed water at a low concentration, such as 50to 100 PPM as measured as free chlorine, and a low temperature, such as10 to 30 degrees Celsius to sterilize or sanitize the caps 104 while thecaps 104 are being loaded and prior to the caps 104 being loaded ontothe cap conveyor 144.

In yet another embodiment of the sterilization system, as illustrated inFIGS. 4A and 4B, the cap station 140 may include an immersion station147. The immersion station 147 may supplement or replace the cap rinser146. The immersion station 147 may be in the form of a tank, vat, orcontainer that is filled with electrolyzed water. The immersion station147 may be in line and connected with the cap conveyor 144. For example,as the caps 104 are conveyed along the cap conveyor 144, the caps 104may be directed or conveyed into the immersion station 147 where thecaps 104 may be completely immersed in electrolyzed water. The caps 104may then be directed or conveyed out of the immersion station and backonto the cap conveyor 144 towards the filling station 160. The immersionstation 147 may be filled with electrolyzed water at a lowconcentration, such as 50 to 100 PPM as measured as free chlorine, and alow temperature, such as 10 to 30 degrees Celsius to sterilize orsanitize the caps 104 while the caps 104 are conveyed through andimmersed in the immersion station 147. Additionally, the immersionstation 147 may be filled with electrolyzed water a higher concentrationand a higher temperature as disclosed above. As was previouslydescribed, a sterile air blower may be included to help remove anyresidual electrolyzed water following the immersion station 147.

Additionally, as illustrated in FIGS. 1A and 1D, the sterilizationsystem may include the filler station 160. The filler station 160 mayconsist of a filler 162 and a filler conveyor system 164. The filler 162may be a rotary filler as illustrated in FIG. 1D. Additionally, thefiller 162 may be other types and/or configurations of filling systemswithout departing from this invention. The filler 162 may receive thebottles 102 from the bottle conveyor 124 and fill the bottles 102 with abeverage using a filling head 168 on the filler 162. Also, the filler162 may include a capper that receives the caps 104 from the capconveyor 144 and places the caps 104 on the bottles 102 after thebottles 102 have been filled. Additionally, there may be a captightening device 166 on the filler 162 to ensure the caps 104 aresealed and tightened onto the bottles 102. The filler 162 may performother operations without departing from this invention, such as sealingthe bottle along the rim of the bottle after filling and prior toplacing the caps 104 on the bottles 102. The filler station 160 alsoincludes a filler conveyor system 164 which may transport the filled andcapped bottles 102 from the filler 162 to a location where the bottles102 can be packed and prepared for shipping.

In an embodiment of this invention, electrolyzed water may be used topre-sterilize the system 100 before the initiation of production andprior to loading and filling the bottles 102 and the caps 104.Additionally, electrolyzed water may be used to sterilize the system 100if sterility is lost, such as for equipment maintenance or componentproblems which require intervention by an operator or technician. Forexample, electrolyzed water may be used for the sterilization ofcritical surfaces on the system. Critical surfaces may include surfacesor equipment on the filler, such as a filling chamber (the internalchamber of the filler 162), the filler heads 168 (which connect orassociate with the bottles 102 to fill the bottles 102 with beverage),the cap tightening device 166 (which tightens the caps 104 onto thebottles 102), or any other surfaces that may contact the areas on thebottles 102 or the caps 104 that may come in contact with the beverage.

Additionally, electrolyzed water may be used to help maintain sterilityof the system 100 and critical surfaces during the filling process. Forexample, as was described above for the bottle rinser 126 and the caprinser 146, the filler station 160 may include a filler spray device170. The filler spray device 170 may consist of one or more nozzles 172.The nozzles 172 may spray electrolyzed water on the bottles 102 and/orcaps 104 throughout the filling process. For example, the nozzles 172may spray electrolyzed water on the bottles 102 when a bottle 102 israised or connected to the filling head 168. Additionally, the nozzles172 may spray electrolyzed water on the capping area, when the caps 104are placed on the bottles 104. This spray of electrolyzed water may berequired to maintain sterilized/clean conditions in the product pathuntil a hermetic seal is accomplished. The nozzles 172 may continuouslyspray the electrolyzed water on the critical surfaces of the system.Additionally the spray of electrolyzed water on the critical surfacesmay be intermittent, such as spraying approximately once every 15seconds, 30 seconds, or every minute, or other time ranges as requiredto maintain sterility of the critical surfaces. Without departing fromthis invention, the filling station may also include a separate capperor capping station that receives the caps 104, places the caps 104 onthe bottles 102, and tightens or seals the caps 104 onto the bottles102. The capping station may be a rotary capper as known and used in theart. This capping station may also include a nozzle that sprayselectrolyzed water on the capping area, where the caps 104 are placedand tightened onto the bottles 102.

As was described above, a small residue may remain on the bottles 102and/or caps 104 after the sterilization. This electrolyzed water thatmay remain on the bottles 102 and/or caps 104 after the sterilization isnot an adulteration issue or product safety issue. In many cases, thereis no significant sensory impact. However, to help remove this residueof electrolyzed water, a sterile air blower 174 may be included with thefiller spray devices 170 without departing from this invention. Thesterile air blower 174 may provide a blow of pressurized sterile air onor inside the bottles 102 and/or the caps 104 during the filling and/orcapping process. The blow of sterile air may be sufficient to remove themajority of residual electrolyzed water.

Specifically, the nozzles 172 spray a pre-set amount of electrolyzedwater on the bottles 102 and/or caps 104 during the filling process. Thefiller spray device 170 may be connected or associated with anelectrolyzed water generator 110. In one embodiment of the invention,the nozzles 172 may spray electrolyzed water at a low concentration, lowtemperature, and a high dwell time. For example, the nozzles 172 mayspray electrolyzed water at a concentration range of approximately 50 to200 PPM as measured as free chlorine, a temperature range ofapproximately 10 to 35 degrees Celsius, and a time range ofapproximately 5 to 30 minutes dwell time. In another embodiment of thisinvention, the nozzles 172 may spray electrolyzed water a highconcentration, high temperature, and a low dwell time. For example, thenozzles 172 may spray electrolyzed water at a concentration range ofapproximately 200 to 1000 PPM as measured as free chlorine, atemperature range of approximately 25 to 60 degrees Celsius, and a timerange of approximately 5 to 30 seconds dwell time.

FIG. 1A also includes a sterilization enclosure 180 as part of thesterilization system 100 described above. This sterilization enclosure180 may be utilized to maintain aseptic conditions for the bottles 102,caps 104, and critical surfaces throughout the filling process. Thesterilization enclosure 180 may provide a controlled environment for aclean/sterilized area within the sterilization enclosure 180. Thesterilization enclosure 180 maintains sterility from theunclean/unsterilized area outside of the sterilization enclosure 180.The sterilization enclosure 180 may be one of many different structuresknown and used in the art. For example, the sterilization enclosure 180may be a cabinet surrounding the clean equipment and sealed to preventany outside contaminants. Additionally, within the sterilizationenclosure 180, a HEPA air filter 182 may be included to help ensureclean and sterilized controlled air within the sterilization enclosure180. The HEPA air filter 182 may provide positive pressure and properflow regimes to help maintain sterility of the bottles 102, caps 104,product, and critical surfaces.

The operation of the sterilization system 100 as illustrated in FIG. 1Amay be accomplished in many different methods. For example, first, thesystem 100 may be pre-sterilized before the initiation of production.Electrolyzed water from an electrolyzed water generator 110 may be usedfor the sterilization of critical surfaces on the system 100 by sprayingelectrolyzed water on the critical surfaces and throughout the system100 within the sterilization enclosure 180.

After the system 100 and critical surfaces are pre-sterilized, thebottles 102 may be loaded into the bottle loader 122. The bottles 102may be loaded into the bottle loader 122 automatically by mechanicalsystems or manually by operators. The bottles 102 will then betransported via the bottle conveyor 124 to the bottle rinser 126. Duringthis transport, the bottles 102 may move along the bottle conveyor 124from the unsterilized or unclean non-aseptic area into the sterilizationenclosure 180 to the sterilized/clean aseptic area.

Once the bottles 102 reach the bottle rinser 126, the bottles 102 may beloaded onto the bottle rinser conveyor 130. The bottles 102 may enterthe bottle enclosure 134 where the bottles 102 will be sprayed withelectrolyzed water. Additionally, the bottle rinser conveyor 130 mayinvert the bottles 102, so that the openings of the bottles 102 arefacing downwardly or to the side. After the bottle rinser conveyor 130inverts the bottles 102, the bottle spray device 128 may sprayelectrolyzed water on the bottles 102 as described above. Following thespraying of the bottles 102, the bottle rinser conveyer 130 may theninvert the bottles 102 to an upright position with the opening facingupward. The bottles 102 will then be loaded back onto the bottleconveyor 124 and transported to the filler station 160.

Additionally, and concurrently to the bottle operation described above,the caps 104 may be loaded into the cap loader 142. Similarly, the caps104 may be loaded automatically into the cap loader 142 by mechanicalsystems or manually by operators. The caps 104 may be transported viathe cap conveyor 144 to the cap rinser 146. During this transport, thecaps 104 may move along the cap conveyor 144 from the unsterilized orunclean non-aseptic area into the sterilization enclosure 180 to thesterilized/clean aseptic area.

Once the caps 104 reach the cap rinser 146, the caps 104 may be loadedonto the cap rinser conveyor 150. The caps 104 may enter the capenclosure 154 where the caps 104 will be sprayed with electrolyzedwater. Additionally, the cap rinser conveyor 150 may invert the caps104, so that the caps 104 are facing downwardly. After the caps 104 havebeen inverted, the cap spray device 148 may spray electrolyzed water onthe caps 104 as described above. Following the spraying of the caps 104,the cap rinser conveyer 150 may then invert the caps 104 to an uprightposition with the opening facing upward. The caps 104 will then beloaded back onto the cap conveyor 144 and transported to the fillerstation 160.

As the bottles 102 reach the filler station 160, the bottles 102 areloaded onto the filler 162 from the bottle conveyor 124. Each of thebottles 102 are then connected to, associated with, attached to, etc.one of the filling heads 168 of the filler 162. The filler sprayingdevice 170 may spray electrolyzed water on the bottles 102 as they arebeing connected to the filling heads 168. After the bottles 102 areconnected to the filling heads 168, the sterile air blower 174 mayprovide a light blow of sterile air onto the bottle area to remove anyresidual electrolyzed water. As the bottles 102 rotate around the filler162, the bottles 102 are filled with a beverage. After the bottles 102have been filled to the appropriate volume, one of the caps 104 from thecap conveyor 144 is placed on each of the bottles 102. Similar to thefilling process, the filler spraying device 170 may spray electrolyzedwater on the bottle/cap area as the caps 104 are placed onto the bottles102. Following the capping process, the sterile air blower 174 mayprovide a blow of pressurized sterile air onto the bottle/cap area toremove any residual electrolyzed water. The filled and capped bottles102 may then be transferred from the filler 162 to the filler conveyor164 where the filled and capped bottles 102 will be transported from thefiller 162 to a location where the bottles 102 can be packed andprepared for shipping.

FIG. 5 illustrates a sterilization system 200 similar to thesterilization system 100 illustrated in FIGS. 1A through 1D andexplained above. The sterilization system 200 includes a bottle station220, a cap station 240, and a filler station 260 similar to thesterilization system 100 in FIGS. 1A through 1D. However, instead of alinear bottle rinser 126 as illustrated in FIG. 1B, the bottle rinser226 depicted in FIG. 5 is a rotary bottle rinser. The bottle rinser 226may include at least one bottle spray device 228. Generally, the bottlerinser 226 may spray or dispense electrolyzed water on the bottles 102as they pass through a given location on the rotary bottle rinser 226.The bottle rinser 226 may include one or more nozzles 232 to sprayelectrolyzed water onto the bottles 102. Specifically, the nozzles 232spray a pre-set amount of electrolyzed water on the bottles 102. Thebottle spray device 226 may be connected or associated with anelectrolyzed water generator 210. In one embodiment of the invention,the nozzles 232 may spray electrolyzed water at a low concentration, lowtemperature, and a high dwell time. For example, the nozzles 232 mayspray electrolyzed water at a concentration range of approximately 50 to100 PPM as measured as free chlorine, a temperature range ofapproximately 10 to 30 degrees Celsius, and a time range ofapproximately 5 to 30 minutes dwell time. In one embodiment of theinvention, the nozzles 232 may spray electrolyzed water at a highconcentration, high temperature, and a low dwell time. For example, thenozzles 232 may spray electrolyzed water at a concentration range ofapproximately 100 to 1000 PPM as measured as free chlorine, atemperature range of approximately 25 to 60 degrees Celsius, and a timerange of approximately 5 to 30 seconds dwell time.

The rotary bottle rinser 226 may be inline with the other conveyorsleading to the filler station 260. Additionally, the rotary bottlerinser 226 may be configured to invert the position of the bottles 102,so that the opening of the bottles 102 are downwardly or side facingwhen the bottles 102 pass by the bottle spray device 228. Once thebottles 102 are sprayed with electrolyzed water, the rotary bottlerinser 226 may then again invert the position of the bottles 102 to anupright position with the opening facing upwardly.

In another embodiment without departing from this invention, asillustrated in FIG. 6, the sterilization system 300 may include a bottlestation 320, a cap station 340, a filler station 360, and asterilization enclosure 380. The bottle station 320 may include amechanical fog generator 332 instead of the nozzles as depicted in FIGS.1A through 1D. The mechanical fog generator 332 may be connected to anelectrolyzed water generator 310. The mechanical fog generator 332 mayproduce small droplets or a fog of electrolyzed water that is dispersedthroughout the sterilization enclosure 380. The fog of electrolyzedwater may sterilize the bottles 102 using electrolyzed water at aconcentration range of approximately 50 to 1000 PPM as measured as freechlorine and a temperature range of approximately 10 to 65 degreesCelsius.

As was described above, a bottle conveyor 324 may be configured toinvert the position of the bottles 102, so that the opening of thebottles 102 are downwardly or side facing when the bottles 102 passthrough the electrolyzed water fog. After the bottles 102 have beensufficiently fogged, the bottle conveyor 324 may again invert theposition of the bottles 102 to an upright position with the openingfacing upwardly.

Additionally, the fog of electrolyzed water may be dispersed within abottle enclosure 334. As was described above, the bottle enclosure 334may be used to contain the electrolyzed water fog. The bottle enclosure334 may include panels that surround an area around or associated withthe area around the mechanical fog generator 332 and the bottle conveyor324. The bottle enclosure 334 may also be a cabinet surrounding thefogging area on the bottles 102.

During the fogging of the bottles 102 with electrolyzed water fog, thebottles 102 may contain a small residue of the electrolyzed water thatmay remain after the sterilization of the bottles 102. The electrolyzedwater inside the bottles 102 is not an adulteration issue or productsafety issue. In many cases, there is no significant sensory impact.However, to help remove this residue of electrolyzed water, a sterileair blower 336 may be included without departing from the invention. Thesterile air blower 336 may provide a pressurized blow of sterile airinside the bottles 102 when the bottle is inverted with the openingfacing downward or with the bottle upright with the opening facingupward. This blow of sterile air may be sufficient to remove themajority of residual electrolyzed water.

As further illustrated in FIG. 6, the capping station 340 may include amechanical fog generator 352 instead of the nozzles as depicted inFIG. 1. The mechanical fog generator 352 may be connected to anelectrolyzed water generator 310. The mechanical fog generator 352 mayproduce small droplets or a fog of electrolyzed water that is dispersedthroughout the sterilization enclosure 380. The fog of electrolyzedwater may sterilize the caps 104 using electrolyzed water at aconcentration range of approximately 50 to 1000 PPM as measured as freechlorine and a temperature range of approximately 10 to 65 degreesCelsius.

As was described above, a cap conveyor 344 may be configured to invertthe position of the caps 104, so that the caps 104 are downwardly orside facing when the caps 104 pass through the electrolyzed water fog.After the caps 104 have been sufficiently fogged, the cap conveyor 344may again invert the position of the caps 104 to an upright positionwith the cap facing upwardly.

Additionally, the fog of electrolyzed water may be dispersed within acap enclosure 354. As was described above, the cap enclosure 354 may beused to contain the electrolyzed water fog. The cap enclosure 354 mayinclude panels that surround an area around or associated with the areaaround the mechanical fog generator 352 and the cap conveyor 344. Thecap enclosure 354 may also be a cabinet surrounding the fogging area onthe caps 104.

During the fogging of the caps 104 with electrolyzed water fog, the caps104 may contain a small residue of the electrolyzed water that mayremain after the sterilization of the caps 104. The electrolyzed waterinside the caps 104 is not an adulteration issue or product safetyissue. In many cases, there is no significant sensory impact. However,to help remove this residue of electrolyzed water, a sterile air blower356 may be included without departing from the invention. The sterileair blower 356 may provide a pressurized blow of sterile air on orinside the caps 104 when the cap is inverted with the opening facingdownward or with the cap upright with the opening facing upward. Thisblow of sterile air may be sufficient to remove the majority of residualelectrolyzed water.

In another embodiment without departing from this invention, themechanical fog generators 332, 352 for the bottles 102 and the caps 104as illustrated in FIG. 6 may be replaced by electrostatically chargedfog generators. In this embodiment, the fog generator produces anelectrostatic-positively charged fog of electrolyzed water.Additionally, the bottles 102, the caps 104, and the critical surfacesmay be negatively charged or grounded, thereby attracting theelectrostatic-positively charged fog of electrolyzed water. The bottles102, the caps 104, and the critical surfaces may act as a magnetattracting the electrostatic-positively charged fog of electrolyzedwater to help sterilize the bottles 102, the caps 104, and the criticalsurfaces.

FIG. 7 illustrates another embodiment of a sterilization system 400 usedto achieve sterile beverages and sterilize bottles 102, caps 104, andcritical surfaces. The bottles 102 may contain the sterile beverage andthe caps 104 may cover the bottles 102. The sterilization system 400 mayinclude a bottle station 420, a cap station 440, a filler station 460,and a sterilization enclosure 480. The sterilization system 400 mayutilize electrolyzed water generated by an electrolyzed water generator410 to sterilize the bottles 102, the caps 104, and the criticalsurfaces.

As illustrated in FIG. 7, the sterilization system 400 may include abottle station 420. The bottle station 420 may include a bottle loader422 and a bottle conveyor(s) 424. The bottle loader 422 may include acontainer that holds fully formed unsterilized or unsanitized emptybottles 102. Additionally, the bottle loader 422 may include a device(not shown) within the container to automatically load the bottles 102on to the bottle conveyor 424. An exemplary configuration of the bottlestation 420 is illustrated in FIG. 7. The bottle station 420 may beother types and/or configurations of bottle stations without departingfrom this invention.

Additionally, as illustrated in FIG. 7, the sterilization system 400 mayinclude a cap station 440. The cap station 440 may include a cap loader442 and a cap conveyor(s) 444. The cap loader 442 may include acontainer that holds unsterilized or unsanitized caps 104. Additionally,the cap loader 442 may include a device (not shown) within the containerto automatically load the caps 104 on to the cap conveyor 444. Anexemplary configuration of the cap station 440 is illustrated in FIG. 7.The cap station 440 may be other types and/or configurations of capstations without departing from this invention.

Additionally, as illustrated in FIG. 7, the sterilization system 400 mayinclude a filler station 460. The filler station 460 may consist of afiller 462 and a filler conveyor system 464. The filler 462 may be arotary filler. Additionally, the filler 462 may be other types andconfigurations of filling systems without departing from this invention.The filler 462 may receive the bottles 102 from the bottle conveyor 424and fill the bottles 102 with a beverage. Also, the filler 462 mayreceive the caps 104 from the cap conveyor 444 and place the caps 104 onthe bottles 102 after the bottles 102 have been filled. Additionally,there may be a cap tightening device 466 on the filler 462 to ensure thecaps 104 are sealed to the bottles 102. The filler 462 may perform otheroperations without departing from this invention, such as placing a sealon the bottle after filling and prior to placing the caps 104 on thebottles 102. The filler station 460 may also include a filler conveyorsystem 464 which transports the filled and capped bottles 102 from thefiller 462 to a location where the bottles 102 can be packed andprepared for shipping.

Additionally, as illustrated in FIG. 7, the sterilization system 400 mayinclude a sterilization enclosure 480. This sterilization enclosure 480may maintain aseptic conditions for the bottles 102, caps 104, andcritical surfaces throughout the filling process. The sterilizationenclosure 480 may provide a controlled environment for theclean/sterilized area inside the sterilization enclosure 480. Thesterilization enclosure 480 maintains sterility from theunclean/unsterilized area outside of the sterilization enclosure 480.The sterilization enclosure 480 may be one of many different structuresknown and used in the art. For example, the sterilization enclosure 480may be a cabinet surrounding the clean equipment and sealed to preventany outside contaminants.

In an embodiment of this invention, electrolyzed water may be used topre-sterilize the system 400 before the initiation of production andprior to loading and filling the bottles 102 and caps 104. Additionally,electrolyzed water may be used to sterilize the system 400 if sterilityis lost, such as for equipment maintenance or component problems whichrequire intervention by an operator or technician. For example,electrolyzed water may be used for the sterilization of criticalsurfaces on the system 400. Critical surfaces may include surfaces orequipment on the filler 462, such as a filling chamber (the internalchamber of the filler 462), the filler heads 468 (which connect orassociate with the bottles 102 to fill the bottles 102 with beverage),the cap tightening device 466 (which tightens the caps 104 onto thebottles 102), or any other surfaces that may contact the areas on thebottles 102 or the caps 104 that may come in contact with the beverage.At least one mechanical fog generator 472 connected to an electrolyzedwater generator 410 may be utilized to provide an electrolyzed water fogthat performs the pre-sterilization functions.

Additionally, electrolyzed water may be used to help maintain sterilityof the system 400 and critical surfaces during the filling process. Forexample, the mechanical fog generator 472 may be connected to anelectrolyzed water generator 410. The mechanical fog generator 472 mayproduce small droplets or a fog of electrolyzed water that is dispersedthroughout the sterilization enclosure 480. The fog of electrolyzedwater may sterilize and maintain sterility of the bottles 102, caps 104,and critical surfaces using electrolyzed water at a concentration rangeof approximately 50 to 1000 PPM as measured as free chlorine and atemperature range of approximately 10 to 65 degrees Celsius. As wasdiscussed above, the electrolyzed water does not provide a productadulteration issue and there may be no significant sensory impact.

The operation of the sterilization system 400 as illustrated in FIG. 7may be accomplished in many different methods. For example, first, thesterilization system 400 may be pre-sterilized before the initiation ofproduction. Electrolyzed water may be used for the sterilization ofcritical surfaces on the system by fogging the system 400 and thecritical surfaces with electrolyzed water within the sterilizationenclosure 480.

After the system 400 and critical surfaces are pre-sterilized, thebottles 102 may be loaded into the bottle loader 422. The bottles 102may be loaded into the bottle loader 422 automatically by mechanicalsystems or manually by operators. The bottles 102 will then betransported via the bottle conveyor 424 to the filler station 460.During this transport, the bottles 102 may move along the bottleconveyor 424 into the sterilization enclosure 480.

Additionally, and concurrently to the bottle operation described above,the caps 104 may be loaded into the cap loader 442. Similarly, the caps104 may be loaded automatically into the cap loader 442 by mechanicalsystems or manually by operators. The caps 104 may be transported viathe cap conveyor 444 to the filler station 460. During this transport,the caps 104 may move along the cap conveyor 444 into the sterilizationenclosure 480.

As the bottles 102 and caps 104 move into the sterilization enclosure480, the electrolyzed water fog produced by the electrolyzed water foggenerator 472 sterilizes the bottles 102 and the caps 104. As thebottles 102 reach the filler, the bottles 102 are loaded into the filler462 from the bottle conveyor 424. Each of the bottles 102 are thenconnected to, associated with, attached to, etc. one of the fillingheads 468 of the filler 462. As the bottles 102 rotate around the filler462, the bottles 102 are filled with a beverage. After the bottles 102have been filled to the appropriate volume, one of the caps 104 from thecap conveyor 444 is placed on the bottle. Throughout the filling andcapping process, the electrolyzed water fog surrounds the process andmaintains sterility of the system. The filled and capped bottles 102 maythen be transferred from the filler 462 to the filler conveyor 464 wherethe filled and capped bottles 102 will be transported from the filler462 to a location where the bottles 102 can be packed and prepared forshipping.

In another embodiment, the mechanical fog generators 472 illustrated inFIG. 7 may be replaced by an electrostatically charged fog generator aswas described above. In this embodiment, the fog generator produces anelectrostatic positively-charged fog of electrolyzed water.Additionally, the bottles 102, the caps 104, and the critical surfacesmay be negatively charged or grounded, thereby attracting theelectrostatic positively-charged fog of electrolyzed water. The bottles102, the caps 104, and the critical surfaces act as a magnet attractingthe electrostatic positively-charged fog of electrolyzed water to helpsterilize and maintain sterility of the bottles 102, the caps 104, andthe critical surfaces.

FIG. 8 illustrates yet another embodiment of a portion of asterilization system that includes an isolator 590 around the criticalsurfaces of the filler 562. In this embodiment, the isolator 590surrounds and provides a controlled environment for the area surroundingthe critical surfaces on the filler 562. The isolator 590 may be one ofmany different structures known and used in the art. For example, theisolator 590 may be a cabinet that surrounds the critical surfaces andis sealed to prevent any outside contaminants. Additionally, any of theabove described methods for pre-sterilization and maintenance ofsterility may be used with the isolator 590 and thesterilization/maintenance of sterility of the critical surfaces. Forexample, the pre-sterilization and maintenance of sterility may beprovided by an electrolyzed water generator 510 that provides: 1)intermittent spray of electrolyzed water from filler nozzles 572 on thecritical surfaces within the isolator 590; 2) a mechanical fog generator573 connected to an electrolyzed water source 510 to provide a fog ofelectrolyzed water throughout the isolator 590; and 3) an electrostaticfog generator connected to an electrolyzed water source to provide anelectrostatic positively-charged fog throughout the isolator 590, or anycombination thereof. In this embodiment, the bottles 102 and/or the caps104 may be sterilized prior to reaching the isolator 590. Additionally,the bottles 102 and/or the caps 104 may not be sterilized prior toreaching the isolator 590, and the means described above, intermittentspray, mechanical fog, or electrostatically charged fog, may be utilizedto sterilize the bottles 102 and/or the caps 104 within the isolator590.

In another embodiment similar to the embodiment illustrated in FIG. 8,the sterilization system may include one or multiple small chambers orenclosures instead of the entire isolator. One or multiple smallchambers may surround or enclose the critical surfaces or critical pathareas identified above, such as the area surrounding the filler headsthat connect to or associate with the bottles 102 to fill the bottles102 with the beverage, or the area surrounding the cap tightening devicethat seals the bottles 102 and tightens the caps 104 onto the bottles102. These small chambers or enclosures need not be fully enclosedaround the area. The small chambers or enclosures may provide positiveair flow protection to maintain sterility or sanitization at thosecritical surfaces and areas, such as with HEPA filtered air or anelectrolyzed fog within the small chamber or enclosure.

The various embodiments of the invention described and illustrated withreference to FIGS. 1A-8 provide several benefits and advantages. First,the safety and health efficacy of electrolyzed water is improved ascompared to the use of other sterilizing agents used in the prior art.Electrolyzed water is considered a very benign chemical as compared toother sterilizing agents used in the prior art. Additionally, there areno food adulteration problems, thereby minimizing any possible consumerissues. Second, this sterilization system can sterilize at a high speedunder a set of conditions, thereby increasing the output of theproduction system. Third, the electrolyzed water can be produced on-siteand as needed. Other chemicals and sterilizing agents need to be orderedand delivered to the production facility. Fourth, there is no rinse stepneeded when using electrolyzed water which reduces water resources. Therinse step required for other sterilizing agents adds increasedequipment costs, increased production time, and increased water (for therinse) usage. Fifth, during changeovers or maintenance work, thepre-sterilization step with electrolyzed water is a shorter timerequirement than is needed for chemical and other sterilization agentchange-overs and maintenance work. Additionally, the use of electrolyzedwater for sterilization allows the use of light weight bottles. Theembodiments of the invention of this sterilization system can be easilyretrofitted with existing hot fill sterilization systems.

The invention herein has been described and illustrated with referenceto the embodiments of FIGS. 1A-8, but it should be understood that thefeatures of the invention are susceptible to modification, alteration,changes or substitution without departing significantly from the spiritof the invention. For example, the dimensions, size and shape of thevarious bottles, caps, conveyors, and other equipment or components maybe altered to fit specific applications. Accordingly, the specificembodiments illustrated and described herein are for illustrativepurposes only and the invention is not limited except by the followingclaims and their equivalents.

1. A sterilization system used to achieve sterile beverages andsterilize bottles and caps, wherein the bottles contain the sterilebeverage and the caps cover the bottles, the sterilization systemcomprising: a bottle sterilizer for sterilizing the bottles, wherein thebottle sterilizer discharges electrolyzed water onto the bottles; a capsterilizer for sterilizing the caps, wherein the cap sterilizerdischarges electrolyzed water onto the caps; and a filler station thatincludes a filler sterilizer and a filler that includes product-contactsurfaces, wherein the filler fills the bottles with the beverage andcaps the bottles, wherein the filler sterilizer sterilizes the fillerstation before the initiation of production by discharging electrolyzedwater on the product-contact surfaces.
 2. The sterilization systemaccording to claim 1, wherein the bottle sterilizer, the cap sterilizer,and the filler sterilizer include a mechanical sprayer that includesnozzles that discharge a spray of electrolyzed water onto the bottles,the caps, and the product-contact surfaces respectively.
 3. Thesterilization system according to claim 2, wherein the spray ofelectrolyzed water is at a concentration range of approximately 50 to100 PPM as measured as free chlorine, a temperature range ofapproximately 10 to 30 degrees Celsius, and a hold time range ofapproximately 5 to 30 minutes.
 4. The sterilization system according toclaim 2, wherein the spray of electrolyzed water is at a concentrationrange of approximately 100 to 1000 PPM as measured as free chlorine, atemperature range of approximately 25 to 65 degrees Celsius, and a holdtime range of approximately 5 to 30 seconds.
 5. The sterilization systemaccording to claim 1, wherein the bottle sterilizer, the cap sterilizer,and the filler sterilizer include a fog generator that discharges a fogof electrolyzed water onto the bottles, the caps, and theproduct-contact surfaces respectively.
 6. The sterilization systemaccording to claim 5, wherein the fog of electrolyzed water isdischarged at a concentration range of approximately 50 to 100 PPM asmeasured as free chlorine and a temperature range of approximately 10 to30 degrees Celsius.
 7. The sterilization system according to claim 5,wherein the fog of electrolyzed water is discharged at a concentrationrange or approximately 100 to 1000 PPM as measured as free chlorine anda temperature range of approximately 25 to 65 degrees Celsius.
 8. Thesterilization system according to claim 1, wherein the bottlesterilizer, the cap sterilizer, and the filler sterilizer include anelectrostatic fog generator that discharges an electrostatically chargedfog of electrolyzed water onto the bottles, the caps, and theproduct-contact surfaces respectively.
 9. The sterilization systemaccording to claim 8, wherein the electrostatically charged fog ofelectrolyzed water is at a concentration range of approximately 50 to100 PPM as measured as free chlorine and a temperature range ofapproximately 10 to 30 degrees Celsius.
 10. The sterilization systemaccording to claim 8, wherein the electro-statically charged fog ofelectrolyzed water is at a concentration range of approximately 100 to1000 PPM as measured as free chlorine and a temperature range ofapproximately 25 to 65 degrees Celsius.
 11. The sterilization systemaccording to claim 1, wherein the electrolyzed water is produced bypassing water through an electrochemical cell which results in twoseparate electrically opposite streams, a first stream that has adisinfectant property and includes a positively charged stream with a pHbetween approximately 6-8, and a second stream that has a detergentproperty and includes a negatively charged stream with a pH betweenapproximately 11 and
 13. 12. A sterilization system used to achievesterile beverages and sterilize bottles and caps, wherein the bottlescontain the sterile beverage and the caps cover the bottles, thesterilization system comprising: an electrolyzed water generator thatproduces electrolyzed water; a bottle station for sterilizing thebottles, the bottle station including a bottle loader for loading thebottles, a bottle conveyor for transporting the bottles, and a bottlerinser located along the bottle conveyor and connected to theelectrolyzed water generator, wherein the bottle rinser sprays theelectrolyzed water onto the bottles; a cap station for sterilizing thecaps, the cap station including a cap loader for loading the caps, a capconveyor for transporting the caps, and a cap rinser located along thecap conveyor and connected to the electrolyzed water generator, whereinthe cap rinser sprays the electrolyzed water on the caps; a fillerstation connected to the bottle station and the cap station, wherein thefiller station includes a filler with critical surfaces that arepotential product-contact surfaces during the filling operation, andwherein the filler fills the bottles with the beverage and caps thebottles after the bottles are filled with the beverage, and wherein thefiller station further includes a spray device connected to theelectrolyzed water generator that sprays the electrolyzed water onto thecritical surfaces of the filler.
 13. The sterilization system accordingto claim 12, wherein the critical surfaces include one or more of thefollowing: internal chamber of the filler, filler heads that connect toor associate with the bottles to fill the bottles with the beverage, ora cap tightening device that tightens the caps onto the bottles.
 14. Thesterilization system according to claim 12, wherein the electrolyzedwater is sprayed at a concentration range of approximately 50 to 100 PPMas measured as free chlorine, a low temperature range of approximately10 to 30 degrees Celsius, and a dwell time range of approximately 5 to30 minutes.
 15. The sterilization system according to claim 12, whereinthe electrolyzed water is sprayed at a concentration range ofapproximately 100 to 1000 PPM as measured as free chlorine, atemperature range of approximately 25 to 65 degrees Celsius, and a dwelltime range of approximately 5 to 30 seconds.
 16. The sterilizationsystem according to claim 12, further comprising a sterilizationenclosure that fully encloses the filler, wherein the sterilizationenclosure maintains aseptic conditions for the bottles, the caps, andthe critical surfaces.
 17. The sterilization system according to claim16, wherein the sterilization enclosure includes a HEPA air filter toprovide positive air pressure and proper air flow regimes throughout thesterilization enclosure.
 18. A sterilization system used to achievesterile beverages and sterilize bottles and caps, wherein the bottlescontain the sterile beverage and the caps cover the bottles, thesterilization system comprising: a bottle station that includes a bottleloader for loading the bottles and a bottle conveyor for transportingthe bottles; a cap station that a cap loader for loading the caps and acap conveyor for transporting the caps; a filler station connected tothe bottle station and the cap station, wherein the filler stationincludes a filler with critical surfaces that are potentialproduct-contact surfaces during the filling operation, and wherein thefiller fills the bottles with the beverage and caps the bottles afterthe bottles are filled with the beverage; a sterilization enclosure thatfully encloses the filler, wherein the sterilization enclosure maintainsaseptic conditions for the bottles, the caps, and the critical surfaces;an electrolyzed water generator that produces electrolyzed water; a foggenerator connected to the electrolyzed water generator, wherein the foggenerator produces a fog of electrolyzed water that is dispersed withinthe sterilization enclosure, wherein the fog of electrolyzed watersterilizes the bottles, caps, and critical surfaces.
 19. Thesterilization system according to claim 18, wherein the criticalsurfaces include one or more of the following: internal chamber of thefiller, filler heads that connect to or associate with the bottles tofill the bottles with the beverage, or a cap tightening device thattightens the caps onto the bottles.
 20. The sterilization systemaccording to claim 18, wherein the electrolyzed water generator produceselectrolyzed water at a concentration range of approximately 50 to 1000PPM as measured as free chlorine.
 21. The sterilization system accordingto claim 18, wherein the fog generator produces an electrostatic,positively-charged fog of electrolyzed water.
 22. The sterilizationsystem according to claim 21, wherein the bottles, the caps, and thecritical surfaces are negatively charged or grounded, wherein thebottles, the caps, and the critical surfaces attract the electrostatic,positively-charged fog of electrolyzed water, thereby sterilizing thebottles, the caps, and the critical surfaces.
 23. A method for achievingsterile beverages and sterilizing bottles and caps comprising:sterilizing the bottles by using electrolyzed water on the bottles;sterilizing the caps by using electrolyzed water on the caps; andsterilizing a filler with electrolyzed water before the initiation ofproduction.